1996 TOYOTA RAV4 Service Repair Manual

S01434
S01364
S01362
S01363
S01283
B
SST
A
− ENGINE MECHANICALENGINE UNIT
EM−71
1996 RAV4 (RM447U)
29. REMOVE FRONT SUSPENSION CROSSMEMBER
(a) Remove the 2 bolts and 2 nuts holding the PS gear as-
sembly to the front suspension crossmember.
(b) Remove the 2 nuts, and disconnect the engine mounting
center member.
(c) Disconnect the TWC w/ pipe from the ring.
(d) Support the front suspension crossmember with a jack.
(e) Remove the 6 bolts and front suspension crossmember.
30. REMOVE ENGINE MOUNTING CENTER MEMBER
(a) Remove the 2 bolts holding the center member to the
front engine mounting insulator.
(b) Remove the 2 bolts holding the center member to the
body, and remove the center member.
31. DISCONNECT PS PUMP FROM ENGINE
(a) Disconnect the 2 air hoses.
(b) Remove the bolt A.
(c) Using SST and a deep socket wrench, loosen the bolt B.
SST 09249−63010
(d) Remove the drive belt.

R10966
S01357
Engine
Hanger
No. 1
S01296
S01350
S01559
Ground Strap
Connector EM−72
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
(e) Remove the 3 bolts, and disconnect the PS pump from
the engine.
HINT:
Suspend the PS pump securely.
32. REMOVE ENGINE AND TRANSAXLE ASSEMBLY
FROM VEHICLE
(a) Install a engine hange No. 1 in the correct direction.
Part No. 1:
Engine hanger No. 1 12281−74060
Bolt 91611−B1020
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Attach the engine sling device to the engine hangers.
(c) Remove the 2 nuts and 2 bolts, and disconnect the LH en-
gine mounting bracket from the mounting insulator.
(d) Disconnect the ground strap connector.
(e) Remove the bolt and 2 nuts, and disconnect the RH en-
gine mounting bracket from the mounting insulator.

S01326
− ENGINE MECHANICALENGINE UNIT
EM−73
1996 RAV4 (RM447U)
(f) Lower the engine out of the vehicle slowly and carefully,
and raise the vehicle.
HINT:
Make sure the engine is clear of all wiring, hoses and cables.
(g) Place the engine and transaxle assembly onto the stand.
33. 2WD:
REMOVE DRIVE SHAFT BEARING BRACKET
34. SEPARATE ENGINE AND TRANSAXLE
(M/T (2WD): See page MX−3)
(M/T (4WD): See page MX−9)
(A/T/A241E (2WD): See page AX−15)
(A/T/A540H (2WD): See page AX−19)
35. M/T only:
REMOVE CLUTCH COVER AND DISC

EM0EX−03
S01296
S01431
S01350
EM−74
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
INSTALLATION
1. M/T only:
INSTALL CLUTCH DISC AND COVER (See page
CL−18)
2. ASSEMBLE ENGINE AND TRANSAXLE
(M/T (2WD): See page MX−7)
(M/T (4WD): See page MX−11)
(A/T/A241E (2WD): See page AX−19)
(A/T/A540H (2WD): See page AX−21)
3. 2WD:
INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
4. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN
VEHICLE
(a) Attach the engine sling device to the engine hangers.
(b) Slowly lower the vehicle, and raise the engine into the en-
gine compartment.
(c) Keep the engine level, and align RH and LH mountings
with the body mountings.
(d) Attach the RH engine mounting bracket to the mounting
insulator, and temporarily install the bolt and 2 nuts.
(e) Attach the LH engine mounting bracket to the mounting
insulator, and install the 2 nuts and 2 bolts.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)

S01559
Ground
Strap
Connector
R10966
S01283
B
SST
A
S01363
− ENGINE MECHANICALENGINE UNIT
EM−75
1996 RAV4 (RM447U)
(f) Tighten the bolt and 2 nuts holding the RH engine mount-
ing bracket to the mounting insulator.
Torque:
37 N·m (380 kgf·cm, 27 ft·lbf) for bolt
52 N·m (530 kgf·cm, 38 ft·lbf) for nut:
(g) Connect the ground strap connector.
(h) Remove the engine sling device from the engine.
(i) Remove the engine hanger No. 1.
5. INSTALL PS PUMP
(a) Install the PS pump with the 3 bolts.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
(b) Install the belt.
(c) Tighten the bolt A.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(d) Using SST and a deep socket wrench, tighten the bolt B.
SST 09249−63010
Torque:
43 N·m (440 kgf·cm, 32 ft·lbf)
30 N·m (300 kgf·cm, 22 ft·lbf) for SST
HINT:
Use a torque wrench with a fulcrum length of 340 mm (13.39
in.).
(e) Connect the 2 air hoses.
6. INSTALL ENGINE MOUNTING CENTER MEMBER
(a) Attach the center member to the body.
(b) Temporarily install the 2 bolts holding the center member
to the body.
(c) Temporarily install the 2 bolts holding the center member
to the front engine mounting insulator.

S01362
S01364
S01434
Z17304BB A EM−76
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
7. INSTALL FRONT SUSPENSION CROSSMEMBER
(a) Support the front suspension crossmember with a jack.
(b) Attach the front suspension crossmember to the body,
and temporarily install the 6 bolts.
(c) Temporarily install the engine mounting center member
with the 2 nuts.
(d) Temporarily install the PS gear assembly with the 2 bolts
and 2 nuts.
(e) Tighten the 6 bolts holding the front suspension cross-
member to the body.
Torque:
206 N·m (2,100 kgf·cm, 152 ft·lbf) for bolt A
137 N·m (1,400 kgf·cm, 101 ft·lbf) for bolt B
(f) Tighten the 2 bolts and 2 nuts holding the PS gear assem-
bly to the front suspension crossmember.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
(g) Tighten the 2 nuts holding the front suspension cross-
member, engine mounting center member to the rear en-
gine mounting insulator.
Torque: 112 N·m (1,140 kgf·cm, 82 ft·lbf)
(h) Tighten the 2 bolts holding the engine mounting center
member to the front engine mounting insulator.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)
(i) Tighten the 2 bolts holding the engine mounting center
member to the body.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
8. INSTALL STABILIZER (See page SA−50)
9. INSTALL FRONT DRIVE SHAFT (See page SA−31)

S01347
S01285
S01432
− ENGINE MECHANICALENGINE UNIT
EM−77
1996 RAV4 (RM447U)
10. 4WD only:
INSTALL PROPELLER SHAFT (See page PR−9)
11. INSTALL A/C COMPRESSOR
(a) Install the A/C compressor with the 2 bolts, stud bolt and
nut.
Torque:
47 N·m (480 kgf·cm, 34 ft·lbf) for stud bolt
37 N·m (380 kgf·cm, 27 ft·lbf) for bolt
27 N·m (280 kgf·cm, 20 ft·lbf) for nut
(b) Connect the A/C compressor connector.
12. INSTALL FRONT EXHAUST PIPE
(a) Place 2 new gaskets to the front and rear of the front ex-
haust pipe.
(b) Temporarily install 3 nuts holding the front exhaust pipe
to the front TWC.
(c) Temporarily install the 2 bolts holding the front exhaust
pipe to the TWC w/ pipe.
(d) Using a 14 mm deep socket wrench, tighten the 3 nuts
holding the front exhaust pipe to the front TWC.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(e) Tighten the 2 bolts holding the front exhaust pipe to the
TWC w/ pipe.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
13. CONNECT ENGINE WIRE TO CABIN
(a) Push in the engine wire through the cowl panel.
(b) Install the wire clamp to the bracket.
(c) Connect the 2 ECM connectors.
(d) Connect the 2 connectors to the connectors on the brack-
et.
(e) Connect the connector to the J/B No. 4.
(f) Install the RH floor carpet center cover.
(g) Install the RH cowl side trim.
(h) Install the RH scuff plate.

S01797
M/T
A/T
S01785
A/T Only
S01351
M/T Only
Back−up Light
Connector EM−78
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
14. CONNECT CONNECTORS, CORD, STRAP AND
HOSES
(a) Connect the vapor pressure sensor connector.
(b) Connect the igniter connector.
(c) Connect the ignition coil connector.
(d) Connect the noise filter connector.
(e) Connect the high−tension cord to the ignition coil.
(f) Connect the MAP sensor connector.
(g) Connect the MAP sensor vacuum hose to the gas filter on
intake manifold.
(h) Connect the brake booster hose to the intake manifold.
(i) 4WD M/T:
Connect the differential lock control solenoid connector.
(j) Connect the ground strap to the cowl.
15. A/T and 4WD w/ M/T:
CONNECT TRANSAXLE OIL COOLER HOSES
16. CONNECT TRANSAXLE CONTROL CABLE(S) TO
TRANSAXLE
17. A/T only:
INSTALL TRANSAXLE CONTROL CABLE TO FRONT
SUSPENSION CROSSMEMBER AND ENGINE
MOUNTING CENTER MEMBER
18. M/T only:
INSTALL CLUTCH RELEASE CYLINDER
(a) Install the release cylinder with the 2 bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
(b) Install the bracket with the bolt, and install the tube to the
bracket with the clamp.
(c) Install the tube with the clamp and bolt.
(d) Connect the back−up light switch connector.
19. CONNECT GROUND CABLE
Connect the ground cable onto the transaxle.
20. M/T only:
INSTALL STARTER (See page ST−19)
21. CONNECT FUEL INLET HOSE TO FUEL FILTER
Connect the inlet hose with 2 new gaskets and the union bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
22. CONNECT HEATER HOSES
23. INSTALL WATER INLET
Install the water inlet with the 2 nuts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
24. INSTALL RADIATOR UPPER AND LOWER HOSES